The MAGMA APPROACH

The unique MAGMA APPROACH, which is fully integrated into MAGMASOFT®, is a systematic methodology to reach desired goals by performing simulations as virtual experiments and put them into action. This methodology helps to simplify complex technical challenges and systematically address them using the appropriate engineering tools available in MAGMASOFT®.

The MAGMA APPROACH provides metal casters, toolmakers and casting users with a new and more efficient means to realize cost reduction and value creation throughout their entire operation. In combination with MAGMASOFT®’s Autonomous Engineering, the MAGMA APPROACH establishes optimized and robust casting and tooling designs and process parameters before production has even begun.

At any stage of product development or improvement processes, the MAGMA APPROACH will guide the MAGMASOFT® user through the following steps:

The first step in the MAGMA APPROACH is to define objectives. The objectives can be any quality, cost, or production driven targets that will be used to determine the best possible designs or process parameters. This can often include the balancing of competing objectives such as reducing shrinkage porosity while achieving the smallest riser size.

Examples:

Set-up a reliable gating and risering or tool design that produces castings to an acceptable quality level

Identify the best compromise between your quality and yield

Determine which parameters have a significant impact on existing casting defects

After determining which objectives are key to success, the next step is to decide which variables to define in an effort to achieve the goals that have been set. Variables can include the variation of any casting or tool dimensions, process parameters or materials.

Now that the complex technical challenge has been simplified by defining objectives, variables to investigate, and key criteria to measure, the engineer will begin utilizing different “tools” available in MAGMASOFT® that will ensure that the required tasks are performed as efficiently as possible. There are many different features in MAGMASOFT® to minimize computational efforts and project set up times. The fully automated simulation set-up loop in MAGMASOFT® reduces engineering time substantially.

Examples:

Easy use of any CAD geometry including built-in parametric modeling

Access to a database of pre-made parametric riser and gating geometries

Automated meshing of any complex shaped project in seconds

Fully autonomous simulation set up loop for running multiple designs

Constraints can be applied to limit the required number of simulations

Automated result evaluation and focused assessment of virtual experiments

Effective statistical tools to reduce the number of virtual experiments required

Autonomous Engineering with MAGMASOFT® offers different strategies to reach the defined goals. These strategies include running individual simulations, setting up a virtual Design of Experiments to test different variables that are of interest, or performing a comprehensive Autonomous Optimization, which uses genetic algorithms. Each, or a combination of these strategies, are used by the engineer based on the technical challenge to be addressed.

Examples:

The freedom to run a single simulation, a parameter study or an Autonomous Optimization at any stage of the development process

Provides decision making tools to investigate a process window with a given set of variables

The final step is to take action based on the insight MAGMASOFT® has provided. This may include cutting tooling based on optimized casting or rigging designs, educating different personnel about the importance of different process variables that have been shown to be critical, or defining ranges for different process variables to ensure a robust SOP and a stable production process. The built-in evaluation and assessment tools facilitate effective communication between different personnel in your company and with your customers.�

Examples:

A comprehensive suite of assessment tools assess data efficiently to gain a better understanding of the impact that each design and process parameter has on casting quality, costs and production efficiencies

Assessment tools ensure that data is used effectively to eliminate defects

The use of quantitative metrics facilitate standardized decision-making processes

Easy to understand charts and graphs aid in effectively explaining and understanding root causes for quality issues and how to control them

The use of quantitative data supports continuous improvement processes during production

By means of Autonomous Engineering, simulations with MAGMASOFT® can be used in an automated virtual test plan to pursue different quality and cost objectives simultaneously.